Minarik PCM23001A User manual

Models:
PCM23001A
PCM23401A
PCM23411A
PCM23000
SERIES
Signal-Following Speed Controls
User’s Manual

Copyright  2002 by
Minarik Corporation
All rights reserved. No part of this manual may be reproduced or transmitted in any
form without written permission from Minarik Corporation. The information and
technical data in this manual are subject to change without notice. Minarik
Corporation and its Divisions make no warranty of any kind with respect to this
material, including, but not limited to, the implied warranties of its merchantability
and fitness for a given purpose. Minarik Corporation and its Divisions assume no
responsibility for any errors that may appear in this manual and make no
commitment to update or to keep current the information in this manual. MVD061002
Printed in the United States of America.

i
Safety Warnings
Note: This symbol denotes an important safety message.
Please read these sections very carefully before performing any
calibration, repair, or other procedure contained in this manual.
• Have a qualified electrical maintenance technician install, adjust,
and service this equipment. Follow the National Electrical Code
and all other applicable electrical and safety codes, including the
provisions of the Occupational Safety and Health Act (OSHA),
when installing equipment.
•Reduce the chance of an electrical fire, shock, or explosion by
proper grounding, over current protection, thermal protection,
and enclosure. Follow sound maintenance procedures.
It is possible for a drive to run at full speed as a result
of a component failure. Minarik strongly recommends the
installation of a master switch in the main power input to
stop the drive in an emergency.
Circuit potentials are at 115 VAC or 230 VAC above earth
ground. Avoid direct contact with the printed circuit board or
with circuit elements to prevent the risk of serious injury or
fatality. Use a non-metallic screwdriver for adjusting the cal-
ibration trimpots. Use approved personal protective equip-
ment and insulated tools if working on this drive with power
applied.

S
H
OCK
HAZARD
AV
O
I
D
HEAT
KEE
DR
O
I
D
A
TI
ON

Safety Warnings i
Specifications 1
Dimensions 2
PCM23001A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PCM23401A/PCM23411A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation 4
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Shielding guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Line fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Line fusing for PCM20000 series drives . . . . . . . . . . . . . . . . . . . .7
Speed adjust potentiometer (Model PCM23001A only) . . . . . . . . . .8
PCM23001A connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Power input connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Line fuse connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Field output connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Current and voltage follower . . . . . . . . . . . . . . . . . . . . . . . . .13
PCM23401A/PCM23411A connections . . . . . . . . . . . . . . . . . . . .15
Power input connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Field output connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Voltage follower connections . . . . . . . . . . . . . . . . . . . . . . . . .17
Operation 19
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
PCM23001A operating modes . . . . . . . . . . . . . . . . . . . . . . . . . .20
Contents
ii

Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Signal Follower Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Signal with Ratio Output . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
PCM23401A/PCM23411A Operating Modes . . . . . . . . . . . . . . .22
Manual/Signal With Ratio Output Mode Selector . . . . . . . . . .22
Manual/Signal Only Mode Select . . . . . . . . . . . . . . . . . . . . . .22
Operating Mode Selector Switch . . . . . . . . . . . . . . . . . . . . . . . .24
Manual/Signal Only Mode Selector . . . . . . . . . . . . . . . . . . . .24
Manual/Signal With Ratio Output Mode Selector . . . . . . . . . .24
Signal Only/Signal With Ratio Output Mode Selector . . . . . . .24
Voltage Select Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Line Voltage (SW501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Motor Armature Voltage (SW502) . . . . . . . . . . . . . . . . . . . . . . .27
Starting the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Line starting and line stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Calibration 28
MIN SPD (Minimum Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
MAX SPD (Maximum Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
SIG MIN (Signal Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
SIG MAX (Signal Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
IR COMP (IR Compensation) . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Troubleshooting 35
Before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Certificate of Compliance 42
Exhibit A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Unconditional Warranty inside back cover
iiiContents

iv
Table 1. Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Table 2. PCM23001A Field Output Connections . . . . . . . . . . . . . . . .11
Table 3. PCM23401A/PCM23411A Field Output Connections . . . . . .17
Table 4. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Table 5. Corcom® Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Table 6. Minarik Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Tables
Figure 1. PCM23001A Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Figure 2. PCM23401A/PCM23411A Dimensions . . . . . . . . . . . . . . . . .3
Figure 3. Speed Adjust Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . .8
Figure 4. PCM23001A Connections . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 5. Voltage Signal Follower Configuration . . . . . . . . . . . . . . . .13
Figure 6. Current Signal Follower Configuration . . . . . . . . . . . . . . . .14
Figure 7. PCM23401A/PCM23411A Connections . . . . . . . . . . . . . . .18
Figure 8. Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Figure 9. Manual/Signal With Ratio Output Mode Select . . . . . . . . . .23
Figure 10. Operating Mode Selector Switch Connections . . . . . . . . .25
Figure 11. Voltage Select Switch Locations . . . . . . . . . . . . . . . . . . . .26
Figure 12. Calibration Trimpot Layout . . . . . . . . . . . . . . . . . . . . . . . .29
Figure 13. PCM23001A IR Comp and Torque Trimpot Settings . . . . .34
Figure 14. PCM23001A Schematic . . . . . . . . . . . . . . . . . . . . . . . . . .39
Figure 15. PCM23401A/PCM23411A Schematic . . . . . . . . . . . . . . . .40
Illustrations

AC Max. Armature Armature
Line Current Voltage Horsepower
Model Voltage (Amps DC) Range Range
PCM23001A
115 10 0 – 90 1/8 – 1
230 10 0 – 180 1/4 – 2
PCM23401A
115 10 0 – 90 1/8 – 1
230 10 0 – 180 1/4 – 2
PCM23411A
115 1.5 0 – 90 1/20 – 1/8
230 1.5 0 – 180 1/10 – 1/4
Form Factor 1.37 at base speed
Acceleration Time 1 second
Deceleration Time 1 second
Load Regulation (at base speed) 2%
Input voltage signal range (input circuit is isolated; S1 to S2) 0-10 VDC
Field Voltage
115 VAC Input 50/100VDC
230 VAC Input 100/200 VDC
Field Current, Maximum 1.0 ADC
Vibration 0.5g max (0 – 50 Hz)
0.1g max (above 50 Hz)
Ambient Temp. Range (PCM23401/PCM23411) 10°C – 40°C
Ambient Temp. Range (PCM23001) 10°C – 55°C
Specifications
1

2
Figure 1. PCM23001A Dimensions
A
K
A
K
2
.30
[
58
]
6.90
[
175
]
6.30
[
160
]
4.40
[
112
]
0.70
[
18
]
3
.00
[
76
]
C5
1
6
SC
R
502
R53
1
D
508
C501
R
525
M
O
V
502
T
501
I
C502
A1
I
C501
C502
A2
SCR
S
W
501
L
F2
S3
S2
S1
M
O
V
503
F1
T50
2
D5
01
D
5
02
NE
G
R
SH
S
I
G
NAL INPU
T
P
OS
C5
1
8
PCM23001A
FOUR MOUNTING SLOTS 0.19 x 3.4 [5 x 9]
ALL DIMENSIONS IN INCHES [MM]
Dimensions

3
PCM23401A/PCM23411A
Dimensions
Figure 2. PCM23401A/PCM23411A Dimensions
7
.
00
[
178
]
FOUR MOUNTING SLOTS 0.19 x 3.4 [5 x 9]
ALL DIMENSIONS IN INCHES [MM]

4
Mounting
Warning
Do not install, rewire, or remove this control with input
power applied. Doing so may cause fire or serious injury.
Make sure you have read and understood the Safety
Warnings before attempting installation.
The chassis must be earth grounded. Use a star washer
beneath the head of at least one of the mounting screws to
penetrate the anodized chassis surface and to reach bare
metal.

•Drive components are sensitive to electrostatic fields. Avoid
direct contact with the circuit board. Hold drive by the chassis
only.
•Protect the drive from dirt, moisture, and accidental contact.
•Provide sufficient room for access to the terminal block and
calibration trimpots.
•Mount the drive away from heat sources. Operate the drive within
the specified ambient operating temperature range.
•Prevent loose connections by avoiding excessive vibration of the
drive.
•Mount drive with its board in either a horizontal or vertical plane.
Four 0.19 in. (5 mm) wide slots in the chassis accept #8 pan
head screws. Fasten either the large base or the narrow flange
of the chassis to the subplate.
Installation

5
Wiring
Installation
•Use 18-24 AWG wire for speed adjust potentiometer wiring. Use
14–16 AWG wire for AC line (L1, L2) and motor (A1 and A2)
wiring.
Warning
Do not install, remove, or rewire this equipment with power
applied. Failure to heed this warning may result in fire, explo-
sion, or serious injury.
This drive is isolated from earth ground. Circuit potentials are
at 115 or 230 VAC above ground. To prevent the risk of injury
or fatality, avoid direct contact with the printed circuit board or
with circuit elements.
Do not disconnect any of the motor leads from the drive
unless power is removed or the drive is disabled. Opening
any one motor lead may destroy the drive.

쇵

6
Shielding guidelines
Warning
Under no circumstances should power and logic leads be
bundled together. Induced voltage can cause unpredictable
behavior any electronic device, including motor controls.

As a general rule, Minarik recommends shielding of all conductors.
If it is not practical to shield power conductors, Minarik
recommends shielding all logic-level leads. If shielding of logic level
leads is not practical, the user should twist all logic leads with
themselves to minimize induced noise.
It may be necessary to earth ground the shielded cable. If noise is
produced by devices other than the drive, ground the shield at the
drive end. If noise is generated by a device on the drive, ground
the shield at the end away from the drive. Do not ground both ends
of the shield.
If the drive continues to pick up noise after grounding the shield, it
may be necessary to add AC line filtering devices, or to mount the
drive in a less noisy environment.
Logic wires from other input devices, such as motion controllers
and PLL velocity controllers, must be separated from power lines in
the same manner as the logic I/O on this drive.
Installation

7
Line fuses
Protect all Minarik drives with AC line fuses. Use fast acting fuses
rated for 250 volts, and approximately 150%–200% of the
maximum armature current.
Line fusing for PCM20000 series drives
Minarik drives require an external fuse for protection. Use fast
acting fuses rated for 250 VAC or higher, and approximately 150%
of the maximum armature current. Fuse both L1 and L2 when the
line voltage is 230 VAC. Fuse blocks are included on cased drives
only.
Table 1 lists the recommended line fuse sizes.
Table 1. Fuse Chart
90 VDC Motor 180 VDC Max. DC Armature AC Line Fuse
Horsepower Horsepower Current (amps) Size (amps)
1/20 1/10 0.5 1
1/15 1/8 0.8 1.5
1/8 1/4 1.5 3
1/6 1/3 1.7 3
1/4 1/2 2.6 5
1/3 3/4 3.5 8
1/2 1 5.0 10
3/4 1 1/2 7.6 15
1 2 10 15
Installation

8Installation
Figure 3. Speed Adjust Potentiometer
WIPER
C
W
W
S
PEED AD
JUST
P
O
TENTI
O
METER
I
N
SU
LATIN
G
DI
S
K
PANEL
S
TAR
WA
S
HER
NUT
MO
UNT THR
O
U
G
H A 0.38 IN.
(
10 MM
)
H
O
L
E
Mount the speed adjust potentiometer through a 0.38 in. (10 mm)
hole with the hardware provided (Figure 3). Install the circular
insulating disk between the panel and the 10K ohm speed adjust
potentiometer.
Twist the speed adjust potentiometer wire to avoid picking up
unwanted electrical noise. If speed adjust potentiometer wires are
longer than 18 in. (457 mm), use shielded cable. Keep speed adjust
potentiometer wires separate from power leads (L1, L2, A1, A2).
Warning
Be sure that the potentiometer tabs do not make contact with
the potentiometer enclosure. Grounding the input will cause
damage to the drive.

Speed adjust potentiometer
(Model PCM23001A only)

9Installation
Connections
Warning
Do not connect this equipment with power applied.
Failure to heed this directive may result in fire or serious
injury.
Minarik strongly recommends the installation of a master
power switch in the voltage input line, as shown in
Figure 4, page 12. The switch contacts should be rated at a
minimum of 200% of motor nameplate current and 250 volts.
The field output is for shunt wound motors only. Do not make
any connections to F1 and F2 when using a permanent
magnet motor.

PCM23001A connections
Connect the power input leads, an external line fuse and a DC
motor to the drive’s printed circuit board (PCB) as shown in Figure
4, page 12.
Power input connections
Connect the AC line power leads to terminals L1 and L2, or to a
double-throw, single-pole master power switch (recommended).

10
Line fuse connections
Wire an external line fuse between the stop switch (if installed) and
the L1 terminal on the PC board. An additional line fuse should be
installed on L2 if the input voltage is 230VAC. The line fuse(s)
should be rated at 250 volts and 150 - 200% of maximum motor
nameplate current. Refer to the line fuse chart on page 7 for fuse
ratings.
Motor connections
Minarik drives supply motor voltage from A1 and A2 terminals. It is
assumed throughout this manual that, when A1 is positive with
respect to A2 , the motor will rotate clockwise (CW) while looking
at the output shaft protruding from the front of the motor. If this is
opposite of the desired rotation, simply reverse the wiring of A1
and A2 with each other.
Connect a DC motor to PCB terminals A1 and A2 as shown in
Figure 4. Ensure that the motor voltage rating is consistent
with the drive’s output voltage.
Installation

11
Field output connections
Use 18 AWG wire to connect the field output to a shunt wound
motor. Table 2 lists the field output connections.
Table 2. PCM23001A Field Output Connections
Line Voltage Approximate Connect Motor
(VAC) Field Voltage (VDC) Field To
115 50 F1 and L1
115 100 F1 and F2
230 100 F1 and L1
230 200 F1 and F2
Warning
The field output is for shunt wound motors only. Do not make
any connections to F1 and F2 when using a permanent mag-
net motor.

Installation

12 Installation
A
G
A
A
K
A
K
-
+
MO
T
O
R
NO
TE:
O
T
CO
NNE
C
T F
USE
O
L2
U
NLE
SS
INP
UT
O
LTA
G
E I
S
2
30
VA
C
M
A
S
TER LIN
E
S
WIT
CH
1
1
5/
2
30
VA
C
P
U
T V
O
LTA
GE
10
K
O
H
M
S
PEED AD
JUST
P
O
TENTI
O
METER
c
w
S3
S2
S
1
C5
1
6
R53
1
D
508
C50
1
R
5
2
5
MO
V
502
T50
1
A1
IC50
1
S
W
502
C502
D
506
L2
L1
MO
V
50
1
F2
S3
S2
S
1
T502
4
3
2
SO50
1
1
S
I
G
MI
N
NE
G
R
SH
D
507
WARNIN
G:
D
O
N
O
T
CO
NNE
CT
FIELD
CO
IL
S
IF
US
IN
G
A
PERMANENT-MA
G
NET M
O
T
O
R
Figure 4. PCM23001A Connections

13
Current and voltage follower
The PCM23001A series drives can be configured to follow a
grounded (non-isolated) voltage or current signal. To configure the
drive to follow a voltage signal, connect the signal leads to the
SIGNAL INPUT POS and SIGNAL INPUT NEG terminals,
observing proper polarity (see Figure 5).
To configure the drive to follow a current signal, install a 1 Kohm,
1/2W resistor across the RSH terminal posts. Connect the signal
leads as you would for a voltage follower application (see Figure 6,
page 14).
90
1
80
S
W
502
5
F2
S3
S2
S
1
MO
V
503
F1
T502
D
50
1
D502
4
3
2
SO50
1
1
NE
G
R
SH
S
I
G
NAL INP
UT
P
OS
C5
1
8
NON-ISOLATED
(GROUNDED)
SIGNAL INPUT
Figure 5. Voltage Signal Follower Configuration
Installation

14 Installation
A
K
G
K
T50
5
A2
D
506
L2
S
W
50
1
L1
M
O
V
50
1
1
1
5
2
30
F2
S3
S2
S
1
MO
V
503
F1
T502
D
50
1
D502
4
3
2
SO50
1
1
NE
G
R
SH
S
I
G
NAL INP
UT
P
OS
C5
1
8
D
507
4 - 20 mADC
SIGNAL INPUT
CO
NNE
C
T 1
000
-
O
H
M
RE
S
I
S
T
O
R A
C
R
OSS
R
SH
T
ERMINAL
S
WHEN
US
E
D
A
S
A
CU
RRENT F
O
LL
O
WER
Figure 6. Current Signal Follower Configuration